Method and system to control vehicle operation

ABSTRACT

Methods and systems are provided for performing a multiple gear downshift of a transmission gear by transiently operating in an intermediate gear. In response to ambient humidity and a condensate level in a charge air cooler, the transmission gear may be downshifted from a higher gear to an intermediate gear, and then to a requested lower gear. Downshifting through an intermediate gear may also be controlled based on the gear shift request.

BACKGROUND/SUMMARY

Turbo charged engines utilize a Charge Air Cooler (CAC) to coolcompressed air from the turbocharger, before it enters the engine.Ambient air from outside the vehicle travels across the CAC to coolintake air passing through the inside of the CAC. Condensate may form inthe CAC when the ambient air temperature decreases, or during humid orrainy weather conditions, where the intake air is cooled below the waterdew point. When the intake air includes recirculated exhaust gasses, thecondensate can become acidic and corrode the CAC housing. The corrosioncan lead to leaks between the air charge, the atmosphere, and possiblythe coolant in the case of water-to-air coolers. Condensate mayaccumulate in the CAC, and then be drawn into the engine at once duringtimes of increased air mass flow, increasing the chance of enginemisfire. Air mass flow may increase to greater levels when downshiftingfrom a higher to a lower transmission gear at wide open throttle. Ifenough condensate has accumulated in the CAC and airflow through the CACincreases to high levels during multiple gear downshifts, engine misfiremay occur.

Other attempts to address engine misfire due to condensate ingestioninvolve avoiding condensate build-up. However, the inventors herein haverecognized potential issues with such methods. Specifically, while somemethods may reduce or slow condensate formation in the CAC, condensatemay still build up over time. If this build-up cannot be stopped,ingestion of the condensate during downshifting, specifically duringdownshifts that skip one or more intermediate gears, may increase thechance of engine misfire.

In one example, the issues described above may be addressed by a methodfor performing a multiple gear downshift in stages, controlling theincrease in air mass flow and condensate purging from the CAC.Specifically, a transmission gear may be downshifted from a higher gearto a lower gear by transiently operating in an intermediate gear beforeshifting to the lower gear. In this way, condensate may be purged fromthe CAC at a lower air mass flow, while in the intermediate gear. Thus,when finally downshifting to the lower gear, engine misfire may bereduced due to increased air mass flow.

As one example, in response to a multiple gear downshift request, atransmission gear may be downshifted from a higher gear to a lower gear.If the requested downshift increases air mass flow to a high level,engine misfire may occur if the amount condensate in the CAC has reacheda threshold level. Condensate may accumulate in the CAC during periodsof lower airflow. Once the threshold level of condensate has beenreached, misfire may be reduced by controlling the execution of arequested multiple gear downshift. For example, in response to amultiple gear downshift request and CAC condensate above a thresholdlevel, the transmission gear may be downshifted from a higher gear to anintermediate gear, and then to the requested lower gear. By holding thetransmission gear at the intermediate gear for a duration, condensatemay be blown off the CAC and into the engine at a slower rate. Then,when shifting to the lower gear, the increase in air mass flow reducesengine misfire since stored condensate has already been purged from theCAC. In this way, engine misfire may be reduced during multiple geardownshifts by utilizing an intermediate gear to control the increase inair mass flow and resulting condensate purging from the CAC.

It should be understood that the summary above is provided to introducein simplified form a selection of concepts that are further described inthe detailed description. It is not meant to identify key or essentialfeatures of the claimed subject matter, the scope of which is defineduniquely by the claims that follow the detailed description.Furthermore, the claimed subject matter is not limited toimplementations that solve any disadvantages noted above or in any partof this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an example engine system including acharge air cooler.

FIG. 2 shows a flow chart illustrating a method for shifting atransmission gear.

FIG. 3 shows a flow chart illustrating a method for performing amultiple gear downshift by transiently operating in an intermediategear.

FIG. 4 shows a flow chart illustrating a method for determining acondensate level at the charge air cooler.

FIG. 5 presents a method for estimating a humidity value used in thecondensate model.

FIGS. 6-7 show example gear shifting operations during different drivingconditions.

DETAILED DESCRIPTION

The following description relates to systems and methods for performinga multiple gear downshift of a transmission gear in an engine system,such as the system of FIG. 1. A gear shift request may be generated inresponse to a change in pedal position. A method for shifting atransmission gear in response to varying shifting requests is presentedin FIG. 2. In response to a request to shift to a new gear, thetransmission may upshift to a higher gear, downshift by a single gear,or downshift by multiple gears. A multiple gear downshift may either beperformed directly from a higher to a lower gear or in stages, bytemporarily downshifting to an intermediate gear based on factorsrelated to condensate release in the charge air cooler. A controller mayperform a control routine, such as the routine of FIG. 3, to determineif an intermediate gear may be used, based on the level of condensate inthe CAC. FIG. 4 presents one method for determining the level ofcondensate in the CAC. This method may be modified by a method forinferring a humidity value, shown at FIG. 5, based on CAC efficiency andwindshield wiper speed. Example shifting operations are shown at FIGS.6-7. In this way, condensate may be purged at a slower rate from a CACby downshifting first to an intermediate gear and then to a lower gearin order to reduce engine misfire.

FIG. 1 is a schematic diagram showing an example engine 10, which may beincluded in a propulsion system of an automobile. The engine 10 is shownwith four cylinders or combustion chambers 30. However, other numbers ofcylinders may be used in accordance with the current disclosure. Engine10 may be controlled at least partially by a control system includingcontroller 12, and by input from a vehicle operator 132 via an inputdevice 130. In this example, input device 130 includes an acceleratorpedal and a pedal position sensor 134 for generating a proportionalpedal position signal PP. Each combustion chamber (e.g., cylinder) 30 ofengine 10 may include combustion chamber walls with a piston (not shown)positioned therein. The pistons may be coupled to a crankshaft 40 sothat reciprocating motion of the piston is translated into rotationalmotion of the crankshaft. Crankshaft 40 may be coupled to at least onedrive wheel of a vehicle via an intermediate transmission system 150.The transmission system 150 may include a multiple fixed gear automatictransmission having a plurality of discrete gear ratios, clutches, etc.In one example, the transmission may have only 8 discrete forward gearsand 1 reverse gear. Further, a starter motor may be coupled tocrankshaft 40 via a flywheel to enable a starting operation of engine10.

An engine output torque may be transmitted to a torque converter (notshown) to drive the automatic transmission system 150. Further, one ormore clutches may be engaged, including forward clutch 154, to propelthe automobile. In one example, the torque converter may be referred toas a component of the transmission system 150. Further, transmissionsystem 150 may include a plurality of gear clutches 152 that may beengaged as needed to activate a plurality of fixed transmission gearratios. Specifically, by adjusting the engagement of the plurality ofgear clutches 152, the transmission may be shifted between a higher gear(that is, a gear with a lower gear ratio) and a lower gear (that is, agear with a higher gear ratio). As such, the gear ratio differenceenables a lower torque multiplication across the transmission when inthe higher gear while enabling a higher torque multiplication across thetransmission when in the lower gear. The vehicle may have six availablegears, where transmission gear six (transmission sixth gear) is thehighest available gear and transmission gear one (transmission firstgear) is the lowest available gear. In other embodiments, the vehiclemay have more or less than six available gears.

As elaborated herein, a controller may vary the transmission gear (e.g.,upshift or downshift the transmission gear) to adjust an amount oftorque conveyed across the transmission and torque converter to vehiclewheels 156 (that is, an engine shaft output torque). Changes in thepedal position signal (PP), in combination with vehicle speed, mayindicate to the controller that a change in transmission gear isrequested. For example, as vehicle speed increases, the controller mayupshift a transmission gear (e.g., from a transmission first gear to atransmission second gear). In one example, the controller may downshifta transmission gear when pedal position increases at a constant vehiclespeed. At a relatively constant throttle opening, as vehicle speedincreases, a transmission gear may be upshifted. Then, as pedal positionincreases, more torque demand may be requested, causing the transmissionto downshift a transmission gear. Then, as vehicle speed increases, thetransmission gear may be upshifted again. Alternatively, as PP decreasesat a given vehicle speed, the controller may downshift a transmissiongear (e.g., from a transmission third gear to a transmission second orfirst gear). The vehicle may upshift or downshift by one or moretransmission gears. Under certain circumstances, the vehicle may performa multiple gear upshift or downshift. For example, downshifts that skipone or more intermediate gears may be referred to as multiple geardownshifts. In one example, the vehicle may be traveling in a highergear when the PP increases by a large amount, such as when the pedal isdepressed fully (wide open pedal (WOP)). In this situation, thecontroller may downshift by multiple gears in order to increase enginespeed torque. The lower gears may then result in higher engine speed(RPM) and vehicle acceleration. For example, the controller maydownshift from a sixth transmission gear to second transmission gear.Thus, the transmission may “skip” three gears and downshift by fourgears. In this way, multiple gear downshifts may be responsive to largeincreases in pedal position, such as WOP, as compared to smallerincreases in pedal position with a downshift among two neighboring gears(e.g., 6^(th) to 5^(th)).

As the vehicle downshifts a transmission gear, and the throttle isopened, the engine speed increases. This increases the air mass flowrate (e.g., air mass flow or mass air flow) through the engine. As such,at lower gears, the air mass flow increases. Air mass flow may furtherincrease during a multiple gear downshift. The controller may measureair mass flow from a mass air flow (MAF) sensor 120, which canapproximate the airflow through a charge air cooler. The controller maythen use this information to control other engine components andprocesses, such as gear shifting. This will be explained further belowwith respect to a charge air cooler and FIGS. 2-4.

Controller 12 is shown in FIG. 1 as a microcomputer, includingmicroprocessor unit 102, input/output ports 104, an electronic storagemedium for executable programs and calibration values shown as read onlymemory chip 106 in this particular example, random access memory 108,keep alive memory 110, and a data bus. Controller 12 may receive varioussignals from sensors coupled to engine 10 for performing variousfunctions to operate engine 10, in addition to those signals previouslydiscussed, including measurement of inducted air mass flow from MAFsensor 120; engine coolant temperature (ECT) from temperature sensor112, shown schematically in one location within the engine 10; a profileignition pickup signal (PIP) from Hall effect sensor 118 (or other type)coupled to crankshaft 40; the throttle position (TP) from a throttleposition sensor, as discussed; and absolute manifold pressure signal,MAP, from sensor 122, as discussed. Engine speed signal, RPM, may begenerated by controller 12 from signal PIP. Manifold pressure signal MAPfrom a manifold pressure sensor may be used to provide an indication ofvacuum, or pressure, in the intake manifold 44. Note that variouscombinations of the above sensors may be used, such as a MAF sensorwithout a MAP sensor, or vice versa. During stoichiometric operation,the MAP sensor can give an indication of engine torque. Further, thissensor, along with the detected engine speed, can provide an estimate ofcharge (including air) inducted into the cylinder. In one example, Halleffect sensor 118, which is also used as an engine speed sensor, mayproduce a predetermined number of equally spaced pulses every revolutionof the crankshaft 40.

Other sensors that may send signals to controller 12 include atemperature sensor 124 at an outlet of a charge air cooler 80, and aboost pressure sensor 126. Other sensors not depicted may also bepresent, such as a sensor for determining the intake air velocity at theinlet of the charge air cooler, and other sensors. In some examples,storage medium read-only memory chip 106 may be programmed with computerreadable data representing instructions executable by microprocessorunit 102 for performing the methods described below as well as othervariants that are anticipated but not specifically listed. Exampleroutines are described herein at FIG. 4.

Combustion chambers 30 may receive intake air from intake manifold 44via intake passage 42 and may exhaust combustion gases via exhaustmanifold 46 to exhaust passage 48. Intake manifold 44 and exhaustmanifold 46 can selectively communicate with combustion chamber 30 viarespective intake valves and exhaust valves (not shown). In someembodiments, combustion chamber 30 may include two or more intake valvesand/or two or more exhaust valves.

Fuel injectors 50 are shown coupled directly to combustion chamber 30for injecting fuel directly therein in proportion to the pulse width ofsignal FPW received from controller 12. In this manner, fuel injector 50provides what is known as direct injection of fuel into combustionchamber 30; however it will be appreciated that port injection is alsopossible. Fuel may be delivered to fuel injector 50 by a fuel system(not shown) including a fuel tank, a fuel pump, and a fuel rail.

Intake passage 42 may include throttle 21 having a throttle plate 22 toregulate air flow to the intake manifold. In this particular example,the position (TP) of throttle plate 22 may be varied by controller 12 toenable electronic throttle control (ETC). In this manner, throttle 21may be operated to vary the intake air provided to combustion chamber 30among other engine cylinders. In some embodiments, additional throttlesmay be present in intake passage 42, such as a throttle upstream of thecompressor 60 (not shown).

Further, in the disclosed embodiments, an exhaust gas recirculation(EGR) system may route a desired portion of exhaust gas from exhaustpassage 48 to intake passage 42 via EGR passage 140. The amount of EGRprovided to intake passage 42 may be varied by controller 12 via EGRvalve 142. Under some conditions, the EGR system may be used to regulatethe temperature of the air and fuel mixture within the combustionchamber. FIG. 1 shows a high pressure EGR system where EGR is routedfrom upstream of a turbine of a turbocharger to downstream of acompressor of a turbocharger. In other embodiments, the engine mayadditionally or alternatively include a low pressure EGR system whereEGR is routed from downstream of a turbine of a turbocharger to upstreamof a compressor of the turbocharger. When operable, the EGR system mayinduce the formation of condensate from the compressed air, particularlywhen the compressed air is cooled by the charge air cooler, as describedin more detail below.

Engine 10 may further include a compression device such as aturbocharger or supercharger including at least a compressor 60 arrangedalong intake manifold 44. For a turbocharger, compressor 60 may be atleast partially driven by a turbine 62, via, for example a shaft, orother coupling arrangement. The turbine 62 may be arranged along exhaustpassage 48. Various arrangements may be provided to drive thecompressor. For a supercharger, compressor 60 may be at least partiallydriven by the engine and/or an electric machine, and may not include aturbine. Thus, the amount of compression provided to one or morecylinders of the engine via a turbocharger or supercharger may be variedby controller 12.

Further, exhaust passage 48 may include wastegate 26 for divertingexhaust gas away from turbine 62. Additionally, intake passage 42 mayinclude a compressor recirculation valve (CRV) 27 configured to divertintake air around compressor 60. Wastegate 26 and/or CRV 27 may becontrolled by controller 12 to be opened when a lower boost pressure isdesired, for example.

Intake passage 42 may further include charge air cooler (CAC) 80 (e.g.,an intercooler) to decrease the temperature of the turbocharged orsupercharged intake gases. In some embodiments, charge air cooler 80 maybe an air to air heat exchanger. In other embodiments, charge air cooler80 may be an air to liquid heat exchanger. CAC 80 may also be a variablevolume CAC. Hot charge air (boosted air) from the compressor 60 entersthe inlet of the CAC 80, cools as it travels through the CAC, and thenexits to enter the engine intake manifold 44. Ambient air flow fromoutside the vehicle may enter engine 10 through a vehicle front end andpass across the CAC, to aid in cooling the charge air. Condensate mayform and accumulate in the CAC when the ambient air temperaturedecreases, or during humid or rainy weather conditions, where the chargeair is cooled below the water dew point. When the charge air includesrecirculated exhaust gasses, the condensate can become acidic andcorrode the CAC housing. The corrosion can lead to leaks between the aircharge, the atmosphere, and possibly the coolant in the case ofwater-to-air coolers. Increased airflow through the CAC may purgecondensate from the CAC. However, if too much condensate is introducedat once into the engine, it may increase the chance of engine misfiredue to the ingestion of water.

Airflow through the CAC increases as air mass flow increases. Air massflow may increase or decrease, depending on vehicle operatingconditions. These conditions may include: whether or not the vehicle istowing a load and which transmission gear the vehicle is operating in.For example, air mass flow may be higher at a second transmission gearthan a fourth transmission gear. In this way, as a transmission geardecreases (when downshifting), air mass flow increases. Further, airmass flow may increase to a greater level when downshifting by multiplegears. For example, when downshifting from a sixth to a fourthtransmission gear, the air mass flow may increase to a first level.However, when downshifting from a sixth to a second transmission gear,the air mass flow may increase to a second level, greater than the firstlevel. Thus, as a transmission gear is downshifted to a lower gear,airflow through the CAC increases.

The airflow through the CAC may reach a level such that condensate isstripped from the CAC and into the intake manifold of the engine.Depending on the CAC design, a threshold level or range of air mass flowmay cause condensate to be purged from the CAC. This threshold range orlevel may be low enough so that the condensate is blown off at a slowenough rate and misfire may not occur. In this way, each CAC may have athreshold range of air mass flow in which the CAC will self-cleanse,without causing misfire.

However, as air mass flow and airflow through the CAC increase further,more condensate may be stripped from the CAC. For example, at lowertransmission gears, airflow may increase, increasing the level ofpurging. As air mass flow and airflow through the CAC increase, the ratethat condensate is purged from the CAC may increase. If a large amountof condensate in the CAC is purged at a high enough rate, engine misfiremay occur. As such, a CAC may have a first threshold level of condensate(first threshold level) in which a certain increase in airflow causesmisfire.

Air mass flow may increase to a level which increases the chance misfireduring certain engine operating conditions, such as during a tip-in orduring a large downshift. For example, during a multiple gear downshiftat WOP, air mass flow may increase above a threshold level; blowing offcondensate from the CAC at an increased rate and increasing the chanceengine misfire if enough condensate has accumulated. As the amount ofdownshift (number of transmission gears) increases, the air mass flow,airflow through the CAC, and chance of engine misfire increases.Different amounts of downshifting may result in the air mass flowincreasing to different levels. For example, as explained above,downshifting from a sixth to a fourth transmission gear may increase theair mass flow to a first level. This first level may not cause misfirefor a certain level of condensate in the CAC. However, when downshiftingfrom a sixth to a second transmission gear, the air mass flow mayincrease to a second level. The second level may cause engine misfirefor the same level of condensate in the CAC. As such, the firstthreshold level of condensate may depend on the specific downshiftrequest.

The first threshold level of condensate may decrease as airflowincreases, since the increased airflow may strip condensate from CAC ata faster rate (e.g., all at once). For example, the first thresholdlevel of condensate may decrease with a larger multiple gear downshiftrequest. In this example, a larger downshift may increase air mass flowto a higher level, increasing the airflow through the CAC and possiblycausing engine misfire. In an alternate example, the first thresholdlevel of condensate may increase with a smaller multiple gear downshift.For example, if the transmission only downshifts by two transmissiongears, air mass flow may increase to a lower level (than downshifting bythree or more transmission gears). Airflow through the CAC may thereforepurge condensate at a slower rate. Thus, a larger amount of CACcondensate may be purged without causing engine misfire. In this way,the first threshold level (of condensate) may be based on an increase inairflow through the CAC at a specific downshift request.

During conditions when airflow through the CAC may increase andcondensate level in the CAC is above a first threshold level, measuresmay be taken to increase air mass flow more slowly, decreasing the rateof condensate purging. Thus, the chance of engine misfire may bereduced. This may be accomplished by a method for downshifting multipletransmission gears (e.g., downshifting by more than one transmissiongear) in stages. For example, instead of shifting directly from a highergear to a lower gear and possibly causing misfire, the controller mayshift the transmission from a higher gear to an intermediate gear, andthen to a lower gear. The intermediate gear may be held briefly (e.g.,several seconds) before shifting to the lower gear. This may allow airmass flow to increase to a first, lower rate, allowing condensate to beblown off into the engine at a slower rate. Thus, the CAC may be quicklycleansed at the intermediate gear while reducing potential for misfire.In one example, condensate may be completely purged from the CAC at theintermediate gear. In another example, an amount of condensate may bepurged at the intermediate gear such that the remaining amount ofcondensate may be purged at the lower gear without causing misfire.Thus, the duration in which the intermediate gear is held may be basedon the amount of condensate in the CAC and the requested gear downshift.For example, at a larger amount of CAC condensate, the duration at theintermediate gear may be longer. In another example, when the requestedgear downshift is smaller (e.g., downshifting by three gear rather thanfour gears), the duration at the intermediate gear may be shorter. Inthis way, the duration at the intermediate gear may be the amount oftime for the CAC condensate level to decrease below a second thresholdlevel, the second threshold level based on the amount of condensate inthe CAC and the requested gear downshift.

In one embodiment, the duration spent in the intermediate gear may bebased on the RPM achieved at the intermediate gear. If the engine speed(RPM) is too high, the lower gear (e.g., final gear) may be selectedhigher that the originally selected lower gear. Specifically, if toomuch time is spent in the intermediate gear, increasing engine speed, ahigher, lower (e.g., final) gear may be selected. For example, if anoriginal gear shift request is from the sixth to the fourth to the thirdtransmission gear, and the duration at the intermediate gear (gear 4)exceeds a threshold, the transmission may instead shift from the fourthto the second transmission gear. In this example, the lower gear ischanged from the third to the second transmission gear. This may furthercontrol condensate purging, reducing misfire risk.

There may be many different combinations and situations for transientlyoperating in an intermediate gear when downshifting a transmission gearfrom a higher gear to a lower gear. Various combinations of higher,intermediate, and lower transmission gears may be used, depending on thedownshift request and engine operating conditions. These engineoperating conditions may include CAC condensate level and air mass flow.In one example, the transmission may downshift from a sixth transmissiongear to a fifth, intermediate, transmission gear, to a second gear (maybe written as 6-4-2). In this example, the intermediate gear is thefourth transmission gear. In another example, the intermediate gear maybe the fifth (6-5-2) or third (6-3-2) transmission gear. In a secondexample, the transmission may downshift from a fifth transmission gearto a fourth, intermediate, transmission gear, to second transmissiongear (5-4-2). In another example, the intermediate gear may be the thirdtransmission gear (5-3-2). Similar combinations may be used with analternate higher gear (e.g., fourth transmission gear) and differentintermediate and lower transmission gears.

In some cases, the downshift from the higher gear to the lower gear maynot increase the air mass flow above the threshold level and causemisfire. Thus, the CAC condensate level may be below the first thresholdlevel. In this situation, the controller may not shift the transmissionto the intermediate gear, but directly to the lower gear. In the casesin which an intermediate gear is needed, the selection of intermediategear may be based on the level (or amount) of condensate in the CAC.Specifically, the intermediate gear may be based on the differencebetween the first threshold level of condensate and the condensate levelin the CAC. For example, if the difference between the first thresholdlevel (of condensate) and the condensate level in the CAC is large(amount of condensate in the CAC is high) and the vehicle is to shiftfrom the sixth to the second transmission gear, the intermediate gearmay be closer to the higher gear (such as five vs. three). In thisexample, shifting 6-3-2 may cause misfire, whereas shifting 6-5-2 mayincrease air mass flow at a slower rate, reducing the chance of misfire.In this way, the intermediate gear may be closer to the higher gear whenthe difference between the first threshold level of condensate and thecondensate level in the CAC is large. Alternatively, the intermediategear may be closer to the lower gear when the difference between thefirst threshold level of condensate and the condensate level is small.

In some embodiments, the controller may adjust engine torque whenperforming a multiple gear downshift in stages by transiently operatingat an intermediate gear. Engine speed and air mass flow may increaseboth when shifting to the intermediate gear and when shifting to thefinal lower gear. In order to go unnoticed by the vehicle operator,engine torque may be adjusted at the intermediate gear if the throttleis not fully open. For example, adjustments to torque may only takeplace if the downshift is performed at part throttle when additionaltorque may be requested by opening up the throttle. If the downshiftmaneuver is performed at WOP, then a trade off of torque andacceleration rate may be made to minimize the risk of misfire. Forexample, some degradation of vehicle performance due to downshifting instages may be less than the degradation and impact to emissions if amisfire occurs due to ingestion of condensate.

The amount or level of condensate in the CAC may be determined, based onengine operating conditions. These may include air mass flow, ambienttemperature and pressure, CAC temperatures and pressures (e.g., at theCAC inlet and outlet), an EGR amount, humidity, and engine load. Thecondensate level may be estimated using a combination of the aboveconditions and/or calculated using a condensate model. Details on thesemethods are presented in detail below with reference to FIGS. 3-5. Thecondensate model, presented at FIG. 4, uses ambient humidity tocalculate the level of condensate in the CAC. Humidity may be determinedfrom a humidity sensor or assumed to be 100%, if a humidity sensor isnot available. However, this may overestimate the condensate formationin the CAC during low humidity weather conditions. Thus, in someexamples, when performing a multiple gear downshift, the controller maydownshift the transmission gear in stages (using an intermediate gear)when CAC condensate is not actually above the first threshold level.

A method for more accurately estimating humidity may improve thecondensate model, allowing multiple gear downshifting through anintermediate gear to occur only when condensate levels in the CAC areactually high (e.g., during high humidity conditions). This method mayinclude setting humidity to a percentage, based on engine operatingconditions. These conditions may include charge air cooler efficiencyand windshield wiper speed. CAC efficiency may be determined from CACinlet an outlet temperatures. For example, at high efficiency levels,the humidity may be set to a higher percentage. In some embodiments, ifCAC efficiency is above a threshold level, humidity may be assumed highand set to 100%. In other embodiments, high humidity may be confirmed bya windshield wiper on/off signal or windshield wiper speed. For example,if the wipers are on, or wiper speed is above a threshold speed, highhumidity may be confirmed and set to 100%. In some examples, thispercentage may be something lower than 100%. In this way, the humidityvalue may be greater for increased CAC efficiency and windshield wiperspeed. In yet another embodiment, wiper speed may be used alone todetermine humidity for the condensate model. Additional embodiments mayinclude an input from a rain sensor used for automatic wiper motor. Therain sensor may determine the rate of rain fall and may be proportionalto the scheduled wiper motor speed.

Methods for downshifting a transmission gear may be responsive to anambient condition, such as ambient humidity. Ambient humidity may bebased on CAC efficiency. A higher ambient humidity may be confirmed at awindshield wiper speed above a threshold speed. Thus, the ambienthumidity value may increase with increasing CAC efficiency andwindshield wiper speed. As humidity increases, the amount of condensatein the CAC may increase. In this way, in response to an ambientcondition and a request to downshift a transmission gear from a highergear to a lower gear, the transmission may be transiently operated at anintermediate gear before shifting to the lower gear. The ambientcondition may be an ambient humidity level or value (e.g., humiditylevel or value). The humidity value may be a percentage. Due toincreased condensate formation, the transient operation at theintermediate gear may be responsive to a higher ambient humidity level.Alternatively, in response to a lower ambient humidity level, thetransmission gear may be shifted directly from the higher gear to thelower gear without operating in the intermediate gear. At lower humiditylevels, there may be less condensate in the CAC. Thus, downshiftingdirectly from a higher gear to a lower gear may not cause enginemisfire. When shifting through an intermediate gear, the intermediategear may be held for a duration, the duration increasing with increasingambient humidity level.

As humidity and the amount of condensate in the CAC increase, the chanceof engine misfire may increase when performing a multiple geardownshift. As such, in response to a condensate level in a CAC and arequest to downshift a transmission gear from a higher gear to a lowergear, the transmission may transiently operate at an intermediate gearbefore shifting to the lower gear. As discussed above, the condensatelevel may be above a first threshold level. The first threshold levelmay be based on an increase in airflow through the CAC at the downshiftrequest.

Turning now to FIG. 2, an example method 200 for shifting a transmissiongear is depicted. In response to a request to shift to a new gear, thetransmission may upshift to a higher gear, downshift by a single gear,or downshift by multiple gears. A multiple gear downshift request mayeither be performed directly (from a higher to a lower gear) or instages, by briefly downshifting to an intermediate gear.

At 202, method 200 includes estimating and/or measuring engine operatingconditions. These may include driver torque demand (based on a pedalposition), engine speed (Ne) and load, ECT, boost level, ambienttemperature and pressure, MAF, MAP, and current transmission gear. Theroutine determines the current gear and pedal position at 204. Thisinformation may be used at 206 to determine whether shifting to a newgear is required. If shifting is not required, the controller maintainsthe current gear at 208 and the method ends. However, if shifting to anew gear is required, the method proceeds to 210 where a downshiftrequest is confirmed. If a downshift to a lower gear is not required,the routines determines the required higher gear at 212 and then shiftsa transmission gear from the current gear to the higher gear.Alternatively, if a downshift is required at 210, the routine determinesat 214 whether the required downshift is a multiple gear downshift(e.g., downshift from a sixth transmission gear to a third transmissiongear). If only downshifting by a single gear is required, the routinedownshifts the transmission by one transmission gear at 216. However, ifa multiple gear downshift is required, the routine determines at 218 howmany gears to downshift the transmission gear by and subsequently, thefinal lower gear.

At 220, the method includes determining whether the multiple geardownshift request may be performed directly or in stages, by brieflydownshifting to an intermediate gear. Downshifting by shifting to anintermediate gear may be based on air mass flow, CAC condensate level,and the requested gear downshift. Details on this method are presentedat FIG. 3. If shifting to an intermediate gear is not needed, theroutine directly downshifts from the higher gear to the lower gear at224. Alternatively, if shifting to an intermediate gear is requested,the routine shifts from the higher gear to the intermediate gear at 222.The controller may hold the transmission at the intermediate gear forduration and then shift to the lower gear. The condensate level in theCAC may then be updated. Additional details on the procedure at 222 arepresented at FIG. 3.

FIG. 3 illustrates an example method 300 for performing a downshift of atransmission gear from a higher gear to a lower gear. During selectconditions, the transmission may transiently operate in an intermediategear before shifting to the lower gear. The transient operation in theintermediate gear may include temporarily engaging the intermediategear, at least partially and optionally fully, during one or more of thetorque phase and inertial phase of the shift. The transient operation inthe intermediate gear may include engagement of transmission clutchesconfigured to engage the intermediate gear, in one example.

At 302, method 300 includes determining the air mass flow (rate), CACconditions (inlet and outlet temperature, inlet and outlet pressure,condensate level, etc.), ambient conditions (ambient temperature andhumidity), MAP, and boost level. An amount or level of condensate in theCAC may be determined based on this data at 304. In one example, at 324,and as further elaborated at the model at FIG. 4, a rate of condensateformation within the CAC may be based on ambient temperature, CAC outlettemperature, air mass flow, EGR, and humidity. This may then be used tocalculate the amount or level of condensate in the CAC. In anotherexample, at 326, a condensation formation value may be mapped to CACoutlet temperature and a ratio of CAC pressure to ambient pressure. Inan alternate example, the condensation formation value may be mapped toCAC outlet temperature and engine load. Engine load may be a function ofair mass, torque, accelerator pedal position, and throttle position, andthus may provide an indication of the air flow velocity through the CAC.For example, a moderate engine load combined with a relatively cool CACoutlet temperature may indicate a high condensation formation value, dueto the cool surfaces of the CAC and relatively low intake air flowvelocity. The map may further include a modifier for ambienttemperature.

Returning to FIG. 3, at 306 the method determines the first thresholdlevel of condensate, based on the increase in airflow through the CAC atthe downshift request. For example, if the downshift request is from thesixth transmission gear to the fourth transmission gear, air mass flowand airflow through the CAC may increase to a first level. This firstlevel of airflow may result in the first threshold level of condensateto be set at a higher value. In another example, if the downshiftrequest is from the sixth transmission gear to the second transmissiongear, air mass flow and airflow through the CAC may increase to a secondlevel, greater than the first. In response, the controller may set thefirst threshold level of condensate to a lower level. In this way, bysetting the first threshold level of condensate based on a predictedincrease in airflow, engine misfire may be reduced. In an alternateexample, the first threshold level of condensate may be a set level,independent of the downshift request. This set first threshold level maybe based on the minimum amount of condensate that may cause misfireduring a multiple gear downshift.

The method at 308 includes determining if the CAC condensate level isabove the first threshold level. If the amount of condensate in the CACis not above the first threshold level, the routine continues to 310were the transmission is shifted from a higher gear to a lower gear, asrequested. However, if the CAC condensate level is greater than thefirst threshold level, the routine continues on to 314. At 314, thecontroller determines the intermediate gear. In some cases, there mayonly be one choice of intermediate gear. For example, when shifting froma fourth to a second transmission gear, the third transmission gear maybe the only option for the intermediate gear. In other cases, there maybe multiple intermediate gear options and the selection of intermediategear may be based on the level (or amount) of condensate in the CAC. Forexample, if the difference between the first threshold level ofcondensate and the condensate level in the CAC is high and the vehiclemust shift from the fifth to the second transmission gear, theintermediate gear may be closer the fifth gear (such as four vs. three).In this example, shifting 5-3-2 may cause misfire, whereas shifting5-4-2 may increase air mass flow to a first, lower rate (at theintermediate gear), reducing the chance of misfire. The gear change mayfurther be based on a target air mass flow rate at the newly selectedgear so that condensate may be purged in such a manner as to reduce thechance of misfire.

After determining the intermediate gear at 314, the routine downshiftsthe transmission gear from the higher gear to the chosen intermediategear at 316. The routine at 316 may also include adjusting enginetorque. Torque adjustments may include, at part throttle increasingthrottle opening to maintain requested torque (limited by the maximumairflow that limits the ingestion of condensate level below the misfirerate). In the event a shift to a lower gear may result in more torquethan requested, reducing throttle opening or retarding spark advance maybe used to match the driver demanded torque level. The intermediate gearis held for duration at 318. In one example, the duration may be apre-set value used for every downshift (e.g., set duration). In anotherexample, the duration may be based on the amount of condensate in theCAC and the requested gear downshift. Specifically, the duration may bethe amount of time for the CAC condensate level to decrease below asecond threshold level. In one example, the second threshold level maybe very low (e.g., zero), such that all the condensate is purged fromthe CAC. In another example, the second threshold level may be an amountof condensate that won't cause misfire at increased airflow. Thus, for alarger amount of CAC condensate, the duration at the intermediate gearmay be longer. In another example, when the requested gear downshift issmaller (e.g., downshifting by three gears rather than four gears), theduration at the intermediate gear may be shorter. In this way, theduration may increase for increasing amounts of condensate in the CAC.After holding the intermediate gear for a duration, the routine at 320includes downshifting from the intermediate gear to the requested lowergear. Finally, at 322, the routine may update the condensate level inthe CAC. In this way, in response to a multiple gear downshift request,when a condensate level in a CAC is greater than a first thresholdlevel, the transmission may be downshifted from a higher gear to anintermediate gear, and then to a requested lower gear. As such,condensate introduction from the CAC into the engine may be controlled,reducing engine misfire events.

FIG. 4 illustrates a method 400 for estimating the amount of condensatestored within a CAC. Based on the amount of condensate at the CACrelative to a threshold value, different downshifting operations, suchas those discussed at FIG. 3, may be initiated.

The method begins at 402 by determining the engine operating conditions.These may include, as elaborated previously at 302, ambient conditions,CAC conditions (inlet and outlet temperatures and pressures, flow ratethrough the CAC, etc.), mass air flow, MAP, EGR flow, engine speed andload, engine temperature, boost, ambient pressure, etc. Next, at 404,the routine determines if the ambient humidity (humidity) is known. Inone example, the ambient humidity may be known based on the output of ahumidity sensor coupled to the engine. In another example, humidity maybe inferred from a downstream UEGO sensor or obtained from infotronics(e.g., internet connections, a vehicle navigation system, etc.) or arain/wiper sensor signal. If the humidity is not known (for example, ifthe engine does not include a humidity sensor), the humidity may be setat 406 based on inferred conditions, as elaborated at FIG. 5. However,if the humidity is known, the known humidity value, as provided by thehumidity sensor, may be used as the humidity setting at 408.

The ambient temperature and humidity may be used to determine the dewpoint of the intake air, which may be further affected by the amount ofEGR in the intake air (e.g., EGR may have a different humidity andtemperature than the air from the atmosphere) and the pressure ratio ofthe CAC pressure to the ambient pressure. The difference between the dewpoint and the CAC outlet temperature indicates whether condensation willform within the cooler, and the mass air flow may affect how muchcondensation actually accumulates within the cooler. Additionally, theinternal design of the CAC may characterized and determine the amount ofcondensate that stays entrained in the air flow, and the amount thatcondenses in the CAC. The entrainment and retention values may bedetermined empirically or modeled from the internal characteristics ofthe internal design of the CAC.

At 410, an algorithm may calculate the saturation vapor pressure at theCAC outlet as a function of the CAC outlet temperature and pressure. Thealgorithm then calculates the mass of water at this saturation vaporpressure at 412. Finally, the condensation formation rate at the CACoutlet is determined at 414 by subtracting the mass of water at thesaturation vapor pressure condition at the CAC outlet and the retentionvalue as determined by empirical determine lookup function or modeledform the internal design of the CAC from the mass of water in theambient air. By determining the amount of time between condensatemeasurements at 416, method 400 may determine the amount of condensatewithin the CAC since a last measurement at 418. The current condensateamount in the CAC is calculated at 422 by adding the condensate valueestimated at 418 to the previous condensate value and then subtractingany condensate losses since the last routine (that is, an amount ofcondensate removed. for example, via purging routines) at 420.Condensate losses may be assumed to be zero if the CAC outlettemperature was above the dew point. Alternatively, at 420, the amountof condensate removed may be modeled or determined empirically as afunction of air mass and integrated down with each software task loop(that is, with each run of routine 400).

FIG. 5 presents a method for estimating a humidity value used in thecondensate model presented at FIG. 4. High humidity (e.g., from thepresence of rain) may be inferred from engine operating conditions, suchas windshield wiper (wiper) operation and/or high CAC efficiency. Byevaluating CAC efficiency and/or wiper speed, a more accurate humidityvalue may be set and used to calculate the condensate level in the CAC.This may then be used to control the downshifting operations describedabove.

Method 500 begins at 502 where the controller determines the inlet andoutlet temperatures of the CAC. These temperatures may be used at 504 toestimate CAC efficiency. For example, a low CAC outlet temperature mayindicate increased cooling of the CAC and a high CAC efficiency value.In another example, higher CAC outlet temperature may result in a lowerCAC efficiency value. If CAC efficiency is high, condensate formation inthe CAC may be higher. During rainy or high humidity ambient conditions,CAC efficiency may increase, increasing condensate formation. Thus, highCAC efficiency values may indicate high humidity conditions. At 506, theroutine determine if the CAC efficiency is greater than a threshold. IfCAC efficiency is not great than this threshold, humidity is set to alower value, X %, (e.g., something less than 40% or a value that resultsin no condensation at the measured CAC outlet temperature) at 508. Inone embodiment, this lower value may be 0%. In another embodiment, thisvalue may be something smaller than 100%.

Returning to 506, if CAC efficiency is greater than the threshold, theroutine may assume rain and/or high humidity. In some embodiments, themethod may end here and set the humidity value to 100% for method 400.In other embodiments, as shown in method 500, the routine may continueon to 512 to determine if wiper speed is greater than a threshold speed.If the wiper speed is not greater than the threshold speed and thewipers have not been activated for a minimum threshold wiper on time,the humidity value may be set to a percentage, Y %, at 514. Thispercentage may be around 80-90%, or some other vale that representslittle accumulation of condensate at the given CAC outlet pressure. Inone example, this percentage may be something greater than 0% but lessthan 100%. In some examples, humidity value Y % may be greater thanhumidity X %. In other examples, humidity values X % and Y % may be thesame. If wiper speed is greater than the threshold speed at 512,rain/high humidity is confirmed and may be set to 100% at 516. Thisvalue is then used at 406 in method 400. In some embodiments, method 500may only include inferring high humidity from wiper speed. In otherembodiments, a wiper on signal, instead of wiper speed, may indicatehigh humidity and set the humidity value to 100%.

Now turning to FIG. 6, graph 600 shows example transmission gearshifting operations during different driving conditions. Specifically,graph 600 shows a change in pedal position (PP) indicative of anoperator torque demand at plot 604, a corresponding change in vehiclespeed is shown at plot 606, and a change in engine speed (Ne or RPM) isshown at plot 608. A change in transmission gear is shown at plot 602where 6 is the highest available gear and 1 is the lowest availablegear. Further, graph 600 shows air mass flow (rate) at plot 610, airflowthrough the CAC at plot 612, and CAC condensate level at plot 614.

Prior to t1, pedal position may be at a low position (plot 604),requesting a small amount of torque and vehicle speed (plot 606). As aresult, the vehicle may begin in a transmission gear 1 (plot 602). Attime t1, a vehicle operator may slowly apply pressure to the acceleratorpedal, resulting in a gradual increase in pedal position (plot 604),vehicle speed (plot 606), and engine speed (plot 608). The increase inpedal position and vehicle speed may generate a request to upshift thetransmission gear. As pedal position continues to increase from time t1to time t2, the transmission gear is shifted into higher gears (plot602). At time t2, pedal position becomes constant and the transmissiongear is maintained at transmission gear 6.

At time t3, pedal position increases (plot 604) and, as a result, adownshift request is generated. A multiple gear downshift may berequested, based on the pedal position increase. The transmission may berequested to downshift by two transmission gears, from transmission gear6 to transmission gear 4. At time t3, the condensate level (plot 614) isbelow first threshold level 616. In response to condensate level belowfirst threshold level 616, the transmission gear is shifted from atransmission gear 6 to transmission gear 4, without operating in anintermediate gear. Shifting without operating in the intermediate gearmay include not shifting into, or out of, or operating at, any of theplurality of intermediate gears between the starting gear and endinggear of the transmission. Further, shifting without operating in theintermediate gear may include not operating in each and every gearintermediate the starting gear and ending gear of the transmissionduring the shift.

Downshifting during the increase in pedal position at time t3 results inan increase in vehicle speed (plot 606) and engine speed (plot 608).Additionally, in response to downshifting from higher transmission gear6 to lower transmission gear 4, air mass flow (plot 610) and airflowthrough the CAC (plot 612) increase between time t3 and time t4,reducing the condensate level in the CAC (CAC cleansing or purging).Since CAC condensate level was below the first threshold level 616 attime t3, engine misfire may not occur during the condensate purging.

Between time t3 and t4 a tip-out may occur, causing the transmission todownshift a transmission gear and air mass flow and airflow through theCAC to decrease. During this time, vehicle speed may continue todecrease. As pedal position again increases (plot 604), the transmissiongear may be upshifted to higher gears, causing engine speed to decreaseand air mass flow to decrease at time t4. Between time t4 and time t5,air mass flow (plot 610) and airflow through the CAC (plot 612) remainlow, while condensate level (plot 614) continues to increase.

At time t5, pedal position increases rapidly, possibly indicating a WOPcondition. This may generate a downshift request from the currenttransmission gear 5 to transmission gear 2. This larger transmissiondownshift request may result in a larger increase in air mass flow andairflow through the CAC. In response to the larger multiple geardownshift request, the controller may decrease the first threshold level616. At time t5, CAC condensate level is above first threshold level616. Thus, in response, transmission gear 5 is first downshifted tointermediate transmission gear 4. Air mass flow (plot 612) and airflowthrough the CAC (plot 612) increase during the downshift. As a result,condensate is blown off the CAC and into the engine, causing condensatelevel (plot 614) to decrease. The intermediate transmission gear 4 isheld for duration d1, until CAC condensate level decreases below thesecond threshold level 618 at time t6. At time t6, the transmission gearis downshifted from intermediate transmission gear 4 to lowertransmission gear 2. Engine speed and vehicle speed increase with eachdownshift. Air mass flow and airflow through the CAC increase to ahigher level, blowing off any remaining condensate from the CAC. Sincecondensate level dropped below the second threshold level 618 before theadditional increase in air mass flow, engine misfire does not occur.

In this way, transiently operating in an intermediate transmission gearallowed condensate to be blown off at a lower air mass flow, reducingthe chance of misfire. If an intermediate gear were not used for thedownshift at time t5, misfire may have occurred when downshiftingdirectly from transmission gear 5 to transmission gear 2.

Returning to graph 600, another sudden increase in pedal position occursat time t7, after an amount of time has elapsed. Before time t7, pedalposition (plot 604), vehicle speed (plot 606), and engine speed (plot608) are at relatively constant levels. Air mass flow (plot 610) andairflow through the CAC (plot 612) remain at low levels and CACcondensate level (plot 614) steadily increases. At time t7, pedalposition increases suddenly and a downshift request is generated. Thedownshift request at t7 may be from transmission gear 4 to transmissiongear 2. This is a smaller downshift request than at time t5. Thus, thesmaller downshift request may increase airflow to a lower level. Inresponse to the smaller multiple gear downshift request, the controllermay increase the first threshold level 616. At time t7, CAC condensatelevel is greater than first threshold level 616. In response, thecontroller may downshift the transmission gear from transmission gear 4to intermediate transmission gear 3. In response to the downshift attime t7, engine speed and vehicle speed increase. This first downshiftincreases air mass flow (plot 610) and airflow through the CAC (plot612), causing condensate to be purged from the CAC and a decrease in CACcondensate level (plot 614). The intermediate gear is held for durationd2, until the condensate level decreases below second threshold level618 at time t8. Since a larger amount of condensate was in the CAC attime 7 than at time t5, duration d2 may be longer than duration d1. Attime t8, the transmission downshifts from intermediate transmission gear3 to lower transmission gear 2. Airflow through the CAC increases to ahigher level (plot 612). However, since CAC condensate level is belowsecond threshold level 618, engine misfire does not occur.

Thus, downshifting a transmission gear may be controlled based oncondensate level in a CAC. During a first condition, as shown at timest5 and t7 in graph 600, when condensate level in a CAC is greater than afirst threshold level, a transmission gear may be shifted from thehigher gear to the requested lower gear by transiently operating in anintermediate gear before shifting to the requested lower gear.Alternatively, during a second condition, as shown at time t3 in graph600, when condensate level in a CAC is less than a first thresholdlevel, a transmission gear may be shifted from a higher gear to a lowergear when requested, without operating in an intermediate gear.

Additional transmission gear shifting operations are shown at FIG. 7.Herein, graph 700 illustrates three different downshifting operationsand the resulting increase in air mass flow and amount of condensatepurged from the CAC. As air mass flow increases, airflow through the CACalso increases. Specifically, a change in transmission gear is shown atplot 702, air mass flow is shown at plot 704, and the amount ofcondensate purged from the CAC (e.g., condensate leaving the CAC) isshown at plot 706. Three different downshifting examples are shown (A,B, and C). Prior to time t1, the vehicle may be in transmission gear 5with a relatively constant air mass flow in all three examples. In afirst example, A, a transmission gear may be downshifted directly fromtransmission gear 5 to transmission gear 1 (plot 702 a) at time t1. Inresponse, air mass flow may increase above a threshold level 708 (plot704 a). This threshold level may be the air mass flow level which causesengine misfire if condensate level is above the first threshold level.As air mass flow increases (plot 704 a), the amount of condensate purgedfrom the CAC increases (plot 706 a). Since air mass flow increasesquickly to a high level, condensate may be blown off at an increasedrate. As a result, a larger amount of condensate may be purged from theCAC between time t1 and time t2. Since air mass flow increases abovethreshold level 708 and blows off a large amount of condensate at once,engine misfire may occur in this example.

In a second example, B, the transmission gear may be downshifted fromtransmission gear 5 to an intermediate transmission gear 3 (plot 702 b)at time t1. In response, air mass flow may increase to a level belowthreshold level 708 (plot 704 b). The increase in air mass flow causescondensate to be purged from the CAC (plot 706 b). However, since airmass flow is lower than in first example A, condensate may be purged ata slower rate. As a result, less condensate may be purged from the CACbetween time t1 and time t2. The intermediate gear may be held for aduration, from time t1 to time t2. Then, at time t2, the transmissiongear may be downshifted from the intermediate transmission gear 3 tolower transmission gear 1. Air mass flow may increase above thresholdlevel 708 (plot 704 b), purging the remaining condensate from the CAC.Only a small amount of condensate is purged from the CAC after time t2.Thus, since most of the condensate was purged with a smaller air massflow at the intermediate gear, engine misfire may not occur. In analternate example, the intermediate gear may be held for a slightlylonger duration to allow all the condensate to purge form the CAC beforedownshifting to the lower gear. This may further decrease the chance ofengine misfire.

While transmission gear 3 was chosen as the intermediate gear in secondexample B, other intermediate gears could have been used. For example,in a third example, C, the transmission gear may be downshifted fromtransmission gear 5 to an intermediate transmission gear 4 (plot 702 c).In this this example, the intermediate gear is closer to the higher gear(transmission gear 5). In response, air mass flow increases to a levelbelow threshold level 708 (plot 704 c), but below the air mass flowlevel in second example B (plot 704 b). Condensate is purged from theCAC at a slower rate than in the first two examples, due to the lowerair mass flow level. Thus, between time t1 and time t2, less condensateis purged from the CAC (plot 706 c). At time t2, the transmission gearis downshifted from the intermediate transmission gear 4 to lowertransmission gear 1. Air mass flow may increase above threshold level708 (plot 704 c), purging the remaining condensate from the CAC. Alarger amount of condensate is purged form the CAC after time t2 than inthe first two examples. However, since a portion of the total condensatein the CAC was purged while in the intermediate gear, engine misfire maynot occur. In alternate examples, the intermediate gear may be held fora longer duration to further decrease the amount of condensate in theCAC and reduce the chance of engine misfire.

In this way, downshifting a transmission gear may be controlled inresponse to pedal position and CAC condensate level to reduce enginemisfire events. In response to a multiple gear downshift request, thedownshift may performed directly (from a higher to a lower gear) or instages, by briefly downshifting to an intermediate gear. If CACcondensate level is greater than a first threshold level, the downshiftmay be performed in stages, using an intermediate gear. However, if theCAC condensate level is less than a first threshold level, thecontroller may perform the downshift directly, shifting from the highertransmission gear to the lower transmission gear, without utilizing anintermediate gear. Thus, based on condensate level in the CAC and thespecific downshift request, downshifting may be controlled to improveengine performance. By first downshifting to an intermediate gear duringselect conditions, the increase in air mass flow may be controlled to alevel that safely purges condensate from the CAC without causingmisfire.

Note that the example control routines included herein can be used withvarious engine and/or vehicle system configurations. The specificroutines described herein may represent one or more of any number ofprocessing strategies such as event-driven, interrupt-driven,multi-tasking, multi-threading, and the like. As such, various acts,operations, or functions illustrated may be performed in the sequenceillustrated, in parallel, or in some cases omitted. Likewise, the orderof processing is not necessarily required to achieve the features andadvantages of the example embodiments described herein, but is providedfor ease of illustration and description. One or more of the illustratedacts or functions may be repeatedly performed depending on theparticular strategy being used. Further, the described acts maygraphically represent code to be programmed into the computer readablestorage medium in the engine control system.

It will be appreciated that the configurations and routines disclosedherein are exemplary in nature, and that these specific embodiments arenot to be considered in a limiting sense, because numerous variationsare possible. For example, the above technology can be applied to V-6,1-4, 1-6, V-12, opposed 4, and other engine types. Further, one or moreof the various system configurations may be used in combination with oneor more of the described diagnostic routines. The subject matter of thepresent disclosure includes all novel and non-obvious combinations andsub-combinations of the various systems and configurations, and otherfeatures, functions, and/or properties disclosed herein.

1. A method for an engine, comprising: in response to an ambientcondition and a request to downshift a transmission gear from a highergear to a lower gear, transiently operating at an intermediate gearbefore shifting to the lower gear.
 2. The method of claim 1, wherein theambient condition is an ambient humidity level.
 3. The method of claim2, wherein transiently operating at the intermediate gear is responsiveto a higher ambient humidity level.
 4. The method of claim 3, furthercomprising, in response to a lower ambient humidity level, shiftingdirectly from the higher gear to the lower gear without operating in theintermediate gear.
 5. The method of claim 2, wherein the intermediategear is held for a duration, the duration increasing with increasingambient humidity level.
 6. The method of claim 2, wherein the ambienthumidity level is based on charge air cooler efficiency.
 7. The methodof claim 3, wherein a higher ambient humidity level is confirmed at awindshield wiper speed above a threshold speed.
 8. The method of claim2, wherein the ambient humidity level is used to determine a condensatelevel in a charge air cooler, the condensate level increasing withincreasing humidity.
 9. A method for an engine, comprising: in responseto a condensate level in a charge air cooler and a request to downshifta transmission gear from a higher gear to a lower gear, transientlyoperating at an intermediate gear before shifting to the lower gear. 10.The method of claim 9, wherein transiently operating at the intermediategear is responsive to the condensate level being above a first thresholdlevel.
 11. The method of claim 10, wherein the first threshold level isbased on an increase in airflow through the charge air cooler at adownshift request.
 12. The method of claim 9, wherein the intermediategear is held for a duration, the duration based on a current level ofcondensate in the charge air cooler at a transmission shift.
 13. Themethod of claim 9, wherein the condensate level is based on ambienthumidity, the ambient humidity increasing with increasing charge aircooler efficiency and windshield wiper speed.
 14. The method of claim 9,wherein the intermediate gear is chosen based on the condensate level inthe charge air cooler.
 15. The method of claim 9, wherein the request todownshift a transmission gear is a multiple gear downshift request. 16.The method of claim 15, wherein the multiple gear downshift request isresponsive to a large increase in pedal position, including wide openpedal.
 17. A method for an engine, comprising: in response to a multiplegear downshift request, responsive to an ambient condition and acondensate level in a charge air cooler being greater than a firstthreshold level, downshifting a transmission from a higher gear to anintermediate gear, and then to a requested lower gear.
 18. The method ofclaim 17, wherein the ambient condition is an ambient humidity.
 19. Themethod of claim 18, wherein the intermediate gear is held for aduration, the duration increasing with increasing ambient humidity andan increasing amount of condensate in the charge air cooler.
 20. Themethod of claim 17, wherein the first threshold level of condensatedecreases with a larger multiple gear downshift request.
 21. The methodof claim 17, wherein the intermediate gear is closer to the higher gearwhen a difference between the first threshold level and the condensatelevel in the charge air cooler is large and the intermediate gear iscloser to the lower gear when the difference between the first thresholdlevel and the condensate level in the charge air cooler is small.
 22. Amethod for an engine, comprising: during a first condition, when acondensate level in a charge air cooler is greater than a firstthreshold level, shifting from a higher gear to a requested lower gearby transiently operating at an intermediate gear before shifting to therequested lower gear; during a second condition, when a condensate levelin a charge air cooler is less than a first threshold level, shiftingfrom a higher gear to a lower gear when requested, without operating inthe intermediate gear.
 23. The method of claim 19, wherein the firstthreshold level is lower when a difference between the higher gear andthe lower gear is larger and the first threshold level is higher whenthe difference between the higher gear and the lower gear is smaller.